WO2019142589A1

WO2019142589A1 - Insulator, and stator and motor comprising said insulator

Info

Publication number: WO2019142589A1
Application number: PCT/JP2018/047014
Authority: WO
Inventors: 菱田　光起; 博米田; 浩勝国友
Original assignee: パナソニックＩｐマネジメント株式会社
Priority date: 2018-01-19
Filing date: 2018-12-20
Publication date: 2019-07-25

Abstract

This insulator 5 comprises: a coil-winding unit 50 on which a coil 7 is wound; a first flange part 51 provided on a core segment 41 side of the coil winding unit 50, the first flange part 51 having a coil introduction groove 53 that guides the coil 7 in the coil-winding unit 50; and a second flange part 52 provided on the tip side of a tooth 42 of the coil-winding unit 50. A spacer 54 for aligning the coil 7 is mounted on the coil-winding unit 50, and is placed in a state in line with the coil 7.

Description

Insulator, stator provided with the same, motor

The present invention relates to an insulator around which a coil is wound, a stator provided with the same, and a motor.

In recent years, the demand for motors has increased in industrial and automotive applications. Among them, there is a demand for improvement in motor efficiency and cost reduction.

It is known to improve the space factor of the coils disposed in the slots of the stator as one method of improving the efficiency of the motor. By improving the space factor of the coil, it is possible to suppress the loss due to the current flowing through the coil when the motor is driven.

As a structure for improving the space factor of the coil, a so-called aligned winding coil is generally known, in which the coil is in a state of being aligned and wound around the teeth of the stator. Configurations have been proposed (see, for example, Patent Documents 1 to 4). For example, Patent Document 1 discloses a configuration in which a step or an inclination is provided inside an end of a cylindrical body of an insulating coil bobbin on which a coil is wound or a ridge portion provided at both ends of the cylindrical body to realize an aligned winding coil. Proposed. Further, according to Patent Document 2, a holding groove for holding a wound coil is provided on a side surface of an insulator which is attached to a tooth and which insulates the coil from the tooth. An arrangement for realizing a coil is disclosed.

Japanese Patent Application Laid-Open No. 11-122855 JP, 2006-115565, A U.S. Pat. No. 6,356,001 WO 2011/118357

By the way, generally, the above-mentioned insulator and coil bobbin are formed by molding a resin material using a mold. On the other hand, since the motor performance varies depending on the user's specifications, even if the same stator core and teeth are used, the wire diameter and the number of turns of the coil are changed to adjust the current value etc. supplied to the coil, and the motor performance is adjusted to the individual specifications. Often included.

However, in the conventional configurations disclosed in

Patent Documents

1 and 2, it is necessary to change the width of the holding groove or to change the width of the step or the inclination angle in accordance with the wire diameter of the coil. In order to form an insulator by re-creating a mold, it has been a factor of cost increase.

The present invention has been made in view of the foregoing, and an object thereof is to provide an insulator capable of aligning wound coils even when the wire diameter and the number of turns of the coil are changed.

In order to achieve the above object, in the insulator according to the present invention, a spacer formed separately from the coil winding portion is attached to the radial end of the coil winding portion. The insulator according to the present invention covers the axial end face of the tooth projecting from the core segment and at least a part of both side surfaces in the circumferential direction, and a coil winding portion on which a coil constituted by a winding is wound; A first ridge portion having a coil introduction groove which is continuously provided on one of a tooth base end side and a tooth tip end side of a winding portion and guides the coil to the coil winding portion, and the coil winding portion An insulator provided with a second ridge portion continuously provided on the other of the tooth base end side and the tooth tip end side, wherein a spacer for aligning the coil is attached to the coil winding portion, It is characterized in that it is disposed in line with the coil.

According to this configuration, the distance between the end of the first layer of the coil and the first or second ridge located at the end of the coil winding can be easily adjusted, and the coil can be aligned. .

The difference between the radial length of the coil winding portion and the radial thickness of the spacer is equal to n times the wire diameter of the coil (n is an integer, the number of turns of the first layer of the coil) Is preferred.

According to this configuration, in the coil winding portion, the radial length of the portion on which the coil is actually wound and the radial length of the first layer of the coil coincide with each other, so the coils are surely aligned and wound. Can be

The coil is wound obliquely with respect to the coil winding portion, and the radial thickness of the spacer is the final circumference of the first layer of the coil wound around the coil winding portion. It is preferable to change on the coil winding part according to the planned winding position.

According to this configuration, even when the coil is wound obliquely to the coil winding portion, the first or second end of the first layer of the coil and the end of the coil winding portion are positioned. The distance to the buttocks can be easily adjusted, and the coils can be aligned and wound.

The spacer may be composed of another wire member wound around the coil winding portion and different from the coil.

According to this configuration, since the spacer can be attached using the winding device used in the winding process of the coil, the manufacturing cost of the insulator can be reduced.

The spacer may be integrally formed with the first ridge or the second ridge.

The spacer is preferably formed of a single-layer resin film having a predetermined thickness or a laminate formed by laminating a plurality of the resin films.

According to this configuration, the overall thickness of the spacer is simply adjusted, and in the coil winding portion, the radial length of the portion where the coil is actually wound and the radial length of the first layer of the coil Can be matched. This allows the coil to be reliably aligned and wound.

The axial height H of the spacer is preferably constant throughout the spacer, and when the half value of the wire diameter of the coil is r, the height H has a relationship of H = r (1 + tan 30 °) It is further preferable that Also, it may be located not only in the axial direction but also around the entire circumference of the coil winding portion.

According to this configuration, when the coil is wound in multiple layers, the coils of the second and subsequent layers can be aligned in the axial direction.

The surface of the coil winding portion is preferably a smooth surface.

According to this configuration, since the same insulator can be used for coils having different wire diameters and the number of turns, cost can be reduced.

In the stator according to the present invention, the insulator is provided on each of axial end faces of the teeth of the core segment, and a stator segment formed by winding a coil formed of a winding around the coil winding portion of the insulator A plurality of the stator segments are connected in an annular shape, and the teeth project radially inward of the annular ring.

According to this configuration, the coil space factor in the stator can be increased.

It is preferable that the coil is aligned and wound around the coil winding portion.

A space between the teeth adjacent in the circumferential direction is configured as a slot for accommodating the coil, and an insulating paper for insulating the core segment and the tooth from the coil is covered in the slot so as to cover the side surface of the tooth And it is preferable to arrange | position so that it may overlap with the said 1st and 2nd collar part of the said insulator in an axial direction.

According to this configuration, electrical insulation can be reliably made between the teeth adjacent in the circumferential direction of the stator.

In the motor according to the present invention, the insulator is provided on each of the axial end faces of the teeth of the core segment, and a plurality of stator segments in which a coil made of a winding is wound on the coil winding portion of the insulator A stator including a plurality of stator segments connected in an annular shape, the stator including a configuration in which the teeth project radially inward of the annular ring, and a predetermined distance from the stator radially inward of the stator And at least a rotor including an open rotational shaft.

According to this configuration, the coil space factor in the stator can be increased, and the efficiency of the motor can be improved.

As described above, according to the present invention, an aligned winding coil can be realized even when coils having different wire diameters are wound.

FIG. 1 is a top view of the motor according to the first embodiment. FIG. 2 is an equivalent circuit diagram of the motor shown in FIG. FIG. 3 is a schematic view of a stator. FIG. 4A is a perspective view showing a portion surrounded by a broken line shown in FIG. FIG. 4B is a side view of the structure shown in FIG. 4A as viewed in the radial direction. FIG. 4C is a side view of the structure shown in FIG. 4A as viewed from the circumferential direction. FIG. 5A is a schematic cross-sectional view of the main part of the insulator on which the coil according to the first embodiment is wound. FIG. 5B is a schematic view of main parts of another insulator around which the coil according to the first embodiment is wound, viewed from the axial direction. FIG. 5C is a schematic cross-sectional view of the structure shown in FIG. 5B. FIG. 6 is a schematic cross-sectional view of the main part of the insulator according to the first modification. FIG. 7A is a schematic cross-sectional view of the main parts of an insulator according to a second modification. FIG. 7B is a schematic cross-sectional view of the main parts of another insulator according to Modification 2. FIG. 8A is a perspective view showing the main parts of an insulator according to a third modification. FIG. 8B is a perspective view of a spacer according to a third modification. FIG. 9A is a perspective view showing the main part of the insulator according to the second embodiment. FIG. 9B is a perspective view of a spacer according to Embodiment 2. FIG. 10A is a schematic cross-sectional view of main parts of an insulator on which a coil according to a second embodiment is wound. FIG. 10B is an enlarged view of a portion surrounded by a broken line in FIG. 10A.

Hereinafter, embodiments of the present invention will be described in detail based on the drawings. The following description of the preferred embodiments is merely exemplary in nature and is in no way intended to limit the invention, its applications or its uses.

(Embodiment 1)
[Configuration of motor and stator]
1 shows a top view showing a motor according to this embodiment, FIG. 2 shows an equivalent circuit diagram of the motor shown in FIG. 1, FIG. 3 shows a schematic diagram of a stator, and the stator 4 is a shaft 2 The figure seen from the axial direction is shown. Note that, for convenience of explanation, in FIGS. 1 and 3, illustration and description of some components and their functions are omitted. For example, the frame and the bus bar are not shown. Further, in FIG. 3, the insulator 5 is not shown. Moreover, the exterior body which accommodates the stator 4 is not shown in figure. The shape of the exterior body is, for example, a cylinder made of metal, a substantially rectangular parallelepiped, a substantially rectangular parallelepiped, a polygonal columnar body or the like, and is appropriately selected according to the specification of the motor 1. The components shown in the drawings are also simplified. For example, the insulator 5 shown in FIG. 1 is partially different from the actual shape, and the coils U1 to W4 and their lead terminals 71 shown in FIG. The shape of the is very different. Further, in FIG. 2, the symbol + indicates the winding start of the coil, and the symbol − indicates the winding end of the coil.

In the following description, the longitudinal direction of the shaft 2 may be referred to as an axial direction, the radial direction of the stator 4 may be referred to as a radial direction, and the circumferential direction of the stator 4 may be referred to as a circumferential direction. Further, in the axial direction, the side on which the lead terminals 71 of the coils U1 to W4 are provided is referred to as "upper" and the opposite side is referred to as "lower", and in the radial direction, the center side of the stator 4, that is, the shaft 2 and The side on which the rotor is provided may be referred to as "inside" and the opposite side, that is, the side of the stator core 40 may be referred to as "outside".

In addition, the lamination direction of the magnetic steel sheets to be described later and the above axial direction are the same direction and are synonymous.

In the following description, the term teeth (plural type of teeth) or tooth will be used selectively. The plurality of teeth projecting in the center direction of the annular stator core is referred to as teeth (a plurality of teeth). Further, among the plurality of teeth of the stator core 40, one tooth is described as a tooth 42. Similarly, a plurality of teeth in the core segment 41 described later is referred to as teeth. Further, one tooth portion of the plurality of tooth portions in the core segment 41 is described as a tooth 42. Incidentally, the above-mentioned Patent Document 3 and Patent Document 4 etc. are known documents in which usage of the words "tooth" and "tooth" is described.

The motor 1 includes a rotor 3 having a shaft 2 which is a rotation shaft of the motor 1, a stator 4 and coils U1 to W4 inside an outer body (not shown).

The rotor 3 includes a shaft 2 and magnets 31 in which N poles and S poles are alternately disposed along the outer peripheral direction of the shaft 2 so as to face the stator 4. In the present embodiment, a neodymium magnet is used as the magnet 31 used for the rotor 3. However, the material, shape, and material of the neodymium magnet can be appropriately changed according to the output of the motor. Further, when viewed from the axial direction, the rotor 3 is disposed radially inward of the stator 4 at a constant distance from the stator 4.

The stator 4 is a cylindrical body configured by connecting a plurality of stator segments 40a in an annular shape. In the stator segment 40a, the insulators 5 are respectively attached to the teeth 42 of the core segment 41 from the upper and lower end faces in the axial direction, and an insulator such as insulating paper 6 is attached between the insulators 5 Windings are wound around the coil winding portion 50 and the arrangement portion of the insulator such as the insulating paper 6 (see FIGS. 4A to 4C) to constitute, for example, the coil U1. The external appearance of the stator segment 40a configured as described above is a columnar body having a substantially sectoral cross-sectional shape.

The stator 4 and the stator segment 40 a have a plurality of core segments 41 and teeth 42 projecting radially inward from the inner circumferences of the core segments 41. The core segment 41 is formed by punching a magnetic steel sheet containing silicon or the like as a core segment sheet which forms a part of a substantially annular stator core sheet. It is a layered product which laminated this board (core segment sheet) in multiple layers. The appearance of the core segment 41 configured as described above is a columnar body having a cross-sectional shape that is a piece-like shape that constitutes a part of a substantially annular stator core sheet. The stacking direction of the plate is a normal direction to the plate surface of the plate. The core segment 41 has a yoke portion 41c and a tooth 42 projecting from a substantially central portion of the yoke portion 41c.

The core segment 41 has a recess 41a formed on one side of the yoke portion 41c located in the circumferential direction, and a protrusion 41b formed on the other side. Both the recess 41a and the protrusion 41b have an axis in each side. It is formed extending in the entire direction. Focusing on one core segment 41, the convex portion 41b of the core segment 41 adjacent in the circumferential direction fits into the concave portion 41a of the core segment 41, and the convex portion 41b of the core segment 41 extends in the circumferential direction. On the other hand, they are fitted and connected to the recesses 41 a of the adjacent core segments 41. The annularly shaped stator core 40 is configured by the core segments 41 adjacent in the circumferential direction being fitted and connected as described above.

As shown in FIGS. 1 and 3, by connecting the core segments 41 to constitute the annular stator core 40, the teeth 42 are arranged at equal intervals along the inner periphery of the stator core 40. Moreover, each space | interval of the tooth 42 adjacent to the circumferential direction comprises the slot 43. As shown in FIG.

In addition, the stator 4 has 12 coils U1 to W4. These coils are attached to each tooth 42 through the insulator 5 and the insulating paper 6 (see FIGS. 4A to 4C). As viewed from the direction, they are disposed in each slot 43. Although not shown, the coils U1 to W4 are each composed of a winding having a circular cross section made of a metal material such as copper with an insulating film applied on the surface, and wound in parallel with the insulator 5 by multilayer winding. It is done. The multi-layer winding refers to a state in which the coil 7 is wound around the insulator 5 in a plurality of layers. Further, "circular" means "circular" including processing tolerance of the winding and deformation of the winding when wound around the tooth 42, and the same applies to the following description. Further, in the following description, when one of the coils U1 to W4 is taken up to describe a structure or the like without specifying the coil U1 to W4, the coil 7 is called.

As shown in FIG. 2, the coils U1 to U4, V1 to V4, and W1 to W4 are connected in series, and three phases of U, V, and W phases are star-connected. In addition, three U-, V- and W-phase currents having a phase difference of 120 ° in electrical angle with each other are supplied to coils U1 to U4, V1 to V4 and W1 to W4, respectively, and excited to generate a rotating magnetic field. . A torque is generated in the rotor 3 by the rotating magnetic field, and the shaft 2 is supported by a bearing (not shown) and rotated.

In the present embodiment, the number of magnetic poles of the rotor 3 is ten in total: five N poles and five S poles facing the stator 4 and the number of slots 43 is twelve, but in particular The present invention is not limited to the above, and may be applied to other combinations of the number of magnetic poles and the number of slots.

[Configuration of main part of stator segment]
4A to 4C respectively show a perspective view of a portion surrounded by a broken line in FIG. 1, and a side view seen from the radial direction and the circumferential direction. Note that the illustration of the coil 7 is omitted in FIGS. 4A to 4C for the convenience of description. Further, the insulating paper 6 sandwiched and attached between the insulator 5 and the core segment 41 and the tooth 42 is also illustrated, but shows the state before being folded so as to be accommodated in the slot 43.

As shown in FIGS. 4A to 4C, insulators 5 having the same shape are respectively attached to the teeth 42 projecting from one core segment 41 from the upper and lower end faces in the axial direction, respectively. The insulating paper 6 is sandwiched between the tooth 42 and the insulator 5. As described above, the insulators 5 are provided so as to cover both axial end surfaces of the tooth 42 and portions near the both end surfaces.

The insulator 5 is an insulating member formed by molding an insulating resin material, and is formed at one end of the coil winding portion 50 on which the coil 7 (see FIGS. 5A to 5C) is wound, and at one end of the coil winding portion 50. It has a first collar 51 and a second collar 52 formed at the other end. In the present embodiment, the first collar 51 is mounted on the core segment 41 side, and the second collar 52 is mounted on the tip of the tooth 42 located radially inward of the stator 4. In addition, the coil introduction groove 53 is formed in the first collar portion 51, and when the coil is wound around the coil winding portion 50, the winding constituting the coil 7 is the coil introduction groove 53. As a result, the winding start portion is guided to the coil winding portion 50 in contact with the inner surface 51a (hereinafter referred to as the inner surface 51a of the first collar portion 51) facing the second collar portion 52 in the first collar portion 51. In the present specification, the winding start portion of the coil 7 refers to the vicinity of the first turn of the first layer coil wound around the coil winding portion 50 in the coil 7.

Of the outer peripheral surface of the coil winding portion 50, the outer

peripheral surfaces

50a and 50b covering both end surfaces in the axial direction of the tooth 42 respectively extend in the axial direction of the tooth 42 from the first collar portion 51 toward the second collar portion 52. It is formed to be monotonously inclined so that the height from the upper side surface or the lower side surface in the axial direction is high. By doing so, it becomes easy to align the coil 7 with the coil winding portion 50. Further, among the outer peripheral surfaces of the coil winding portion 50, surfaces 50c, 50d covering both circumferential end surfaces of the tooth 42 are formed to be orthogonal to the axial upper end surface of the tooth 42, respectively. In the following description, the outer circumferential surfaces 50a to 50d may be referred to as the surface of the coil winding portion 50. Also, “perpendicular” means “perpendicular” including the processing tolerance of the insulator 5, the processing tolerance of the tooth 42, and the assembly tolerance when attaching the insulator 5 to the tooth 42, and “parallel” means the insulator 5 It means “parallel” including the processing tolerance of and the assembly tolerance at the time of attaching the insulator 5 to the tooth 42, and the same applies to the following description.

The inner surface 51 a of the first flange portion 51 is a surface provided parallel to a surface orthogonal to the axial upper end surface or the axial lower end surface of the tooth 42.

More specifically, between the surface of the coil winding portion 50 and the opposing surface of the first ridge portion 51 of the second ridge portion 52 (hereinafter referred to as the inner surface 52 a of the second ridge portion 52). A spacer 54 is attached to the corner of the. The spacer 54 is formed separately from the insulator main body 5a (see FIGS. 5A to 5C) including the first ridge 51 and the second ridge 52 including the coil winding portion 50 and the coil introduction groove 53. It is attached to the rotary unit 50. When the first and / or

second flanges

51 and 52 are formed separately from the coil winding portion 50, the portion integrally formed including the coil winding portion 50 is referred to as the insulator main body 5a. Sometimes. Further, unless otherwise specified, the insulator main body 5a is collectively molded of an insulating resin material. The structure of the spacer 54 will be described in detail later.

The insulator 5 has a function to electrically insulate the core segment 41 and the tooth 42 from the coil 7 together with the insulating paper 6. Further, the insulator 5 has a function of stably maintaining the alignment winding of the coil 7 described later.

The insulating paper 6 is impregnated with, for example, an insulating oil, so as to cover both side surfaces of the tooth 42 in the circumferential direction, and in the axial direction with the first and

second flange portions

51, 52 of the insulator 5, respectively. It is arranged so as to partially overlap. Further, although not shown, the insulating paper 6 is folded so as to cover the inside of the slot 43 when assembling the motor 1. As a result, the core segment 41 and the tooth 42 and the coil 7 can be electrically isolated from each other, and the core segment 41 and the tooth 42 adjacent in the circumferential direction can be electrically isolated.

[Configuration of main part of insulator]
FIG. 5A is a cross-sectional schematic view of the main part of the insulator on which the coil according to the present embodiment is wound, and FIG. 5B is an axial view of the main part of another insulator on which the coil according to the present embodiment is wound. FIG. 5C shows a cross-sectional schematic view of the structure of FIG. 5B. Although the insulator 5 shown in FIGS. 5A to 5C is the same as that shown in FIGS. 4A to 4C, the structure of the insulator 5 is simplified and shown in FIGS. 5A to 5C for the convenience of description. Moreover, in FIG. 5A, 5C, the part extended outside through the coil introduction groove 53 among the coil introduction groove 53 and the coil 7 is abbreviate | omitting illustration.

As shown in FIGS. 5A to 5C, the coil 7 is wound around the coil winding unit 50, and the spacer 54 is mounted on the coil winding unit 50 in a state of being lined with the coil 7.

The spacer 54 is a C-shaped (see FIG. 8B) insulating member formed by molding an insulating resin material. Further, the spacer 54 mounted on the coil winding portion 50 is disposed along the root of the second flange 52 with respect to the outer peripheral surfaces 50a to 50c, and the spacer 54 with respect to the outer peripheral surface 50d. Because of the notches, they are not disposed entirely but only partially along the root of the second flange 52. The spacer 54 may be disposed along the root of the second ridge 52 with respect to three continuous surfaces among the outer peripheral surfaces 50a to 50d. Further, if the insulators 5 are of the division type mounted from the upper and lower end surfaces in the axial direction of the tooth 42, the spacers 54 may be mounted on the respective insulators 5. Although not shown, the spacer 54 is positioned and attached to the coil winding portion 50 and fixed to the surface of the coil winding portion 50. In fixing the spacer 54, an adhesive, a fastening member such as a screw, or another fixing member such as a pin can be used.

In addition, it is general that the winding which comprises the coil 7 forms an insulating film in the surface of the electric wire which consists of copper etc. FIG. Therefore, the wire diameter of the coil 7 means the wire diameter including the thickness of the insulating film. Therefore, the wire diameter of the coil 7 shown in FIGS. 5A to 5C is a value obtained by adding twice the thickness of the insulating film to the wire diameter of the wire.

In the case where the coil 7 is wound orthogonally to the coil winding portion 50 in the axial direction, or when the coil 7 is wound with an inclination, the inclination angle of the coil 7 is small because the wire diameter is small When L is small, as shown in FIG. 5A, the radial thickness L1 of the spacer 54 is constant over the outer peripheral surfaces 50a to 50c of the coil winding portion 50 to which the spacer 54 is attached. By doing this, the difference between the radial length L2 of the coil winding portion 50 and the radial thickness L1 of the spacer 54 is n times the wire diameter of the coil 7 (n is an integer, The number of turns in the first layer can be made. In addition, although the case where the wire diameter of the coil 7 is less than 1 mm means the case where the wire diameter of the coil 7 is small, for example, it is not specifically limited to this. Further, in the present specification, “constant” means constant including processing tolerance of the spacer 54.

Further, as shown in FIGS. 5B and 5C, the thickness L1 in the radial direction of the spacer 54 is not constant, and may be changed on the outer circumferential surface 50a. The reason is described below.

When the coil 7 is wound around the coil winding portion 50 through the coil introduction groove 53, the winding of the coil 7 is bent at the outlet of the coil introduction groove 53, and the winding is inclined. It is wound around the outer peripheral surface 50a. Therefore, the distance between the final periphery of the first layer of the coil 7 and the second ridge portion 52 is not constant, and changes on the outer peripheral surface 50 a of the coil winding portion 50. In the spacer 54, the radial thickness L1 changes in accordance with the change in the distance. That is, the thickness L 1 in the radial direction of the spacer 54 changes in accordance with the planned winding position of the final circumference of the first layer of the coil 7 with respect to the coil winding portion 50. By doing this, the difference between the radial length L2 of the coil winding portion 50 and the radial thickness L1 of the spacer 54 is always equal to the diameter of the wire diameter of the coil 7 in the winding direction of the coil winding portion 50. It is made to be n times. Similarly, the thickness L1 in the radial direction of the spacer 54 also changes on the outer circumferential surface 50b.

[Effects, etc.]
As described above, the insulator 5 according to the present embodiment covers the axial end face of the tooth 42 protruding from the core segment 41 and at least a part of both side surfaces in the circumferential direction, and the coil 7 formed of a winding is wound A first winding portion having a coil winding portion 50 to be wound and a coil introduction groove 53 continuously provided on the base end side of the tooth 42 in the coil winding portion 50 and guiding the coil 7 to the coil winding portion 50 51 and a second flange 52 provided continuously on the tip end side of the tooth 42 in the coil winding part 50.

In the insulator 5, the spacer 54 is attached to the coil winding portion 50 in a state of being aligned with the coil 7. Specifically, the spacer 54 is attached to the corner between the inner surface 52 a of the second flange 52 and the coil winding unit 50.

By this, the space | interval of the last periphery of 1st layer of the coil 7 and the 2nd collar part 52 can be adjusted simply, and the coil 7 can be made into an alignment winding. Also, when winding the coil 7 having a different wire diameter or the number of turns around the insulator 5, as disclosed in Patent Document 2, the width of the holding groove of the coil provided in the insulator is changed, or As disclosed in Document 1, it is not necessary to change the width or the inclination angle of the step provided in the insulator. That is, the surface of the coil winding portion 50 may be a smooth surface, and only by changing the spacer 54, the insulator main body 5a having the same shape can be used. As a result, it is possible to suppress an increase in the manufacturing cost of the insulator 5 and to reduce the development cost when developing various motors.

The shape of the spacer 54 is set such that the difference between the radial length L2 of the coil winding portion 50 and the radial thickness L1 of the spacer 54 is n times the wire diameter of the coil 7. That is, the spacer 54 is formed so that the radial length of the coil winding portion 50 on which the coil 7 is actually wound matches the radial length of the first layer of the coil 7 and the coil winding portion It is attached to 50. By this, the coil 7 can be reliably wound in alignment. Further, the thickness L1 in the radial direction of the spacer 54 corresponds to the planned winding position of the final circumference of the first layer of the coil 7 on the outer

peripheral surfaces

50a and 50b which are both axial end surfaces of the coil winding portion 50. It is changing. Thus, the difference between the radial length L2 of the coil winding portion 50 and the radial thickness L1 of the spacer 54 over the entire circumferential direction of the coil winding portion 50 is n times the wire diameter of the coil 7 The coil 7 can be reliably wound in alignment.

In addition, by applying the insulator 5 according to the present embodiment to, for example, the stator 4 of the motor 1 shown in FIG. 1, alignment winding of the coil 7 can be achieved, and a dead space in which the coil 7 in the coil winding unit 50 is not wound. Can be reduced. By this, the space factor of the coil 7 in the slot 43 can be increased, and the efficiency of the motor 1 can be improved. The space factor of the coil 7 can be further increased by making the radial thickness L 1 of the spacer 51 smaller than the wire diameter of the coil 7.

<Modification 1>
FIG. 6 shows a schematic cross-sectional view of the main part of the insulator according to the present modification. For convenience of explanation, the structure of the insulator 5 is shown in a simplified manner in FIG. Moreover, in FIG. 6, the part extended outside through the coil introduction groove 53 among the coil introduction groove 53 and the coil 7 is abbreviate | omitting illustration.

In the configuration shown in the first embodiment, the spacer 54 is an insulating member formed by molding an insulating resin, while in the present modification, the spacer 55 is formed of another linear member different from the coil 7. Differ in that they By forming the wire member around the coil winding portion 50 to form the spacer 55, the spacer 54 does not have to be formed separately, so the manufacturing cost of the insulator 5 can be further reduced. In addition, when winding the spacer 55 around the coil winding portion 50, an existing winding device can be used, and can be shared with the winding device of the coil 7. In addition, by adjusting the wire diameter and the number of turns of the spacer 55, the thickness of the spacer 55 in the radial direction can be set to a desired value, and the coil 7 can be wound in alignment. Further, as described above, even in the case where the coil 7 is wound diagonally with respect to the coil winding portion 50, the spacer 55 of the present modification can cope with it. Furthermore, since the insulating film is provided also on the spacer 55, insulation can be maintained between the tooth 42 and the coil 7 or in the winding of the coil 7 adjacent in the circumferential direction. The spacer 55 may be a wire made of an insulating material if it can be wound by an existing winding device.

Further, although not shown, the winding constituting the spacer 55 is introduced into the coil winding portion 50 through the spacer introduction groove 531 provided in the second flange portion 52. Further, the winding end portion of the spacer 55 is also drawn out through the spacer introducing groove 531 or a spacer introducing groove (not shown) provided separately, and the width of the winding can be adjusted. A special member or adhesive for fixing the end portion outside the coil winding portion 50 can be eliminated.

<Modification 2>
FIG. 7A shows a cross-sectional schematic view of the main part of the insulator according to this modification, and FIG. 7B shows a cross-sectional schematic view of the main part of another insulator according to this modification. For convenience of explanation, the structure of the insulator 5 is simplified and illustrated in FIGS. 7A and 7B. Further, in FIGS. 7A and 7B, a portion of the coil introducing groove 53 and the coil 7 extending to the outside through the coil introducing groove 53 is not shown.

In the configuration shown in the first embodiment, the spacer 54 is attached to the corner between the inner surface 52a of the second flange 52 and the coil winding portion 50, while in the present modification, the spacer 56a is the second It differs in that it is integrally formed with a part of the collar 52 or the spacer 56 b is integrally formed with the second collar 52 itself.

By making the

spacers

56a and 56b have such a configuration, the difference between the radial length L2 of the coil winding portion 50 and the radial thickness of the

spacers

56a and 56b can be reliably made n of the wire diameter of the coil 7 It can be doubled. Thereby, the coil 7 can be wound in alignment with the coil winding portion 50. In addition, when the insulator 5 is a division | segmentation type, the spacer 56a shown to FIG. 7A can be mounted | worn easily. In addition, after the separately formed insulator main body 5a (in this case, the coil winding portion 50 and the first ridge portion 51) is attached to the tooth 42, the spacer 56b shown in FIG. The insulator 5 may be attached to the tooth 42 after the spacer 56b is attached to the insulator main body 5a.

<Modification 3>
FIG. 8A shows a perspective view of the main part of the insulator according to this modification, and FIG. 8B shows a perspective view of the spacer. In addition, illustration of the insulating paper 6 is abbreviate | omitted in FIG. 8A for convenience of explanation. In the configuration shown in the first embodiment, the spacer 54 is attached to the corner between the inner surface 52a of the second flange 52 and the surface of the coil winding portion 50, while in this modification, the first ridge is attached. The difference is that a spacer 57 is attached to a corner portion between the inner surface 51a of the first collar portion 51 and the surface of the coil winding portion 50 in contact with the portion 51a. The spacer 57 is a C-shaped insulating member in which a portion corresponding to the coil introduction groove 53 is cut out.

Such a spacer 57 may be attached to the coil winding portion 50, and also in the case of this modification, the radial length L2 of the coil winding portion 50 can be adjusted by adjusting the radial thickness of the spacer 57. And the radial thickness of the spacer 57 can be n times the wire diameter of the coil 7. This allows the coil 7 to be aligned and wound.

The spacer 55 shown in the first modification may be attached to the corner between the inner surface 51 a of the first flange 51 and the surface of the coil winding unit 50. In that case, the spacer introduction groove 531 is provided in the first ridge 51 separately from the coil introduction groove 53. Further, the

spacers

56a and 56b shown in the second modification may be integrally formed with the first collar portion 51.

Alternatively, the spacer (film spacer) 57 may be formed by punching or cutting an insulating resin film having a predetermined thickness. A spacer is obtained by attaching a laminated body in which a spacer (film spacer) 57 made of a resin film of the same shape is laminated in a single layer or a plurality of spacers (film spacers) 57 is laminated to one type of insulator main body 5a. The entire thickness of the coil 57 can be simply adjusted, and the difference between the radial length L2 of the coil winding portion 50 and the radial thickness of the spacer 57 can be n times the wire diameter of the coil 7. In other words, the coil 7 can be reliably aligned by winding so that the radial length of the coil winding portion 50 where the coil 7 is actually wound matches the radial length of the first layer of the coil 7. can do. In addition, since the spacer (film spacer) 57 does not have to be formed individually according to the wire diameter and the number of turns of the coil 7, the manufacturing cost of the insulator 5 can be further reduced. Such a spacer (film spacer) 57 may be attached to a corner between the inner surface 52 a of the second flange 52 and the surface of the coil winding unit 50. If the thickness of the spacer (film spacer) 57 is smaller than the wire diameter of the coil 7 used, the difference between the radial length L2 of the coil winding portion 50 and the radial thickness of the spacer 57 is made finer It becomes easy to adjust. The material of the spacer (film spacer) 57 is preferably acrylic, polyimide, nylon or polypropylene, from the viewpoint of having insulation properties and facilitating processing.

Second Embodiment
FIG. 9A shows a perspective view of the main part of the insulator according to the present embodiment, and FIG. 9B shows a perspective view of the spacer. FIG. 10A shows a cross-sectional schematic view of the main part of the insulator around which the coil is wound, and FIG. 10B shows an enlarged view of a portion surrounded by a broken line in FIG. 10A. 9A to 10B, the structure of the insulator 5 is simplified and illustrated for convenience of the description. Further, in FIG. 9A, illustration of the insulating paper 6 is omitted. Moreover, in FIG. 10A, the part extended outside through the coil introducing groove 53 among the coil introducing groove 53 and the coil 7 is not shown.

In the configuration shown in the first embodiment, the spacer 54 is attached to the corner between the inner surface 52a of the second flange 52 and the surface of the coil winding portion 50, while in the configuration shown in the present embodiment, The difference is that

spacers

58, 581 are attached to the corner between the inner surface 51a of the first collar 51 and the surface of the coil winding portion 50 in contact with the first collar 51. In the

spacers

58 and 581, a plate-like insulating member 58b (hereinafter simply referred to as a plate-like member 58b) is integrally formed at a central portion of a U-shaped insulating member 58a (hereinafter simply referred to as a U-shaped member 58a). It is formed. Further, the U-shaped member 58 a of the spacer 58 is attached to the outer circumferential surfaces 50 a, 50 c, 50 d of the surface of the coil winding portion 50. The plate-like member 58 b is in contact with the bottom of the coil introduction groove 53, and extends into the inside thereof and is mounted on the coil winding portion 50. By providing the plate-like member 58 b, the handling of the spacer 58 is facilitated, and the spacer 58 can be easily fixed to the coil winding portion 50. Further, by providing the plate-like member 58 b inside the coil introducing groove 53, the coil 7 can be prevented from being affected when wound around the coil winding portion 50. It is preferable to increase the circumferential width and radial thickness of the plate-like member 58a to such an extent that it does not act as a barrier when the winding of the coil 7 is passed through the coil introduction groove 53. The ease of handling the spacer 58 and the fixing stability to the coil winding portion 50 can be further improved. In the insulator 5 shown in FIG. 9A, the coil introduction groove 53 is provided on the upper side in the axial direction of the first collar 51, but if the coil introduction groove 53 is also provided on the lower side in the axial direction, The plate-like member of the spacer 581 extends inside the coil introduction groove 53 located on the lower side in the axial direction.

Further, the U-shaped member 58a and the plate member 58b both have the same thickness. Therefore, when the spacer 58 is attached to the coil winding portion 50, the axial height H of the spacer 58 is constant throughout the spacer 58, with the surface of the coil winding portion 50 as a reference surface. Similarly, the axial height of the spacer 581 is also constant throughout the spacer 581. Moreover, as shown to FIG. 10B, this height H is set so that the relationship of the following formula | equation (1) may be satisfy | filled.

H = r (1 + tan 30 °) (1) (r is half of the wire diameter R of the coil 7)

As described above, in order to make the coil 7 be wound in alignment and in multiple layers, the radial length of the coil 7 and the radial direction of the coil winding portion 50 where the coil 7 is actually wound using the spacer 54 etc. Not only the length of the coil 7 but also the positions of the windings of the coil 7 in the same layer, that is, the heights of the coil 7 in the axial direction need to be matched. If the heights are greatly different, winding distortion of the coil 7 occurs, and it becomes impossible to realize aligned winding. In particular, in the second layer of the coil 7, the first winding, which is the winding start, is between the final circumference of the first layer of the coil 7 and the first or

second flange

51 or 52 in the vicinity thereof. Depressed, the axial height may be different from the other circumferential windings.

In the present embodiment, by making the axial height H of the spacer 58 larger than the above-mentioned half value r, in the second layer of the coil 7, the first turn winding is axially lower than the predetermined position. The second layer of the coil can be aligned and wound easily. In particular, when the axial height H of the spacer 58 is defined so as to satisfy the relationship of the equation (1), in the second layer of the coil 7, the first turn winding and the second turn winding have the same height. The second layer of the coil can be reliably aligned and wound.

As a result, as shown in FIG. 10A, the heights of the windings around each of the third and subsequent layers of the coil 7 become uniform, and a multilayer wound and aligned coil 7 can be realized with certainty.

In addition, the relationship of Formula (1) is materialized including the process tolerance of the spacer 58, and the process tolerance of the coil 7. FIG. That is, in the equation (1), the right side and the left side may not be completely the same value. For example, as shown in equation (2), the height H may be within a predetermined range.

0.9 r (1 + tan 30 °) <H <1.1 r (1 + tan 30 °) (2)

In addition, the relationship of Formula (2) is an illustration to the last, and it can correct | amend by the wire diameter of the coil 7, the number of layers, etc.

The radial thickness of the U-shaped member 58 a is preferably equal to r, which is a half value of the wire diameter of the coil 7. By satisfying such a relationship, in the second layer of the coil 7, the first turn winding abuts on the first collar portion 51, and the coil 7 can be reliably aligned and wound. Note that "equal" in this case is equal including the processing tolerance of the spacer 58 and the processing tolerance of the coil 7. However, when the radial thickness of the U-shaped member 58 a is defined equal to the above half value r, the difference between the radial length L 2 of the coil winding portion 50 and the radial thickness of the spacer 58 is the coil 7 It may not be n times the wire diameter of In that case, the radial thickness of the spacer 58 is defined with priority given to the latter relationship.

Further, as shown in the first embodiment, when the spacer 54 is attached to the corner between the inner surface 52a of the second flange 52 and the coil winding portion 50, the height in the axial direction of the spacer 54 is the formula ( The relationship of 1) may be satisfied. Also in this case, in the second layer of the multilayer wound coil 7, it is possible to eliminate the step between the first and second turns, or the step between the last and the previous turn. The coil 7 can be reliably wound in alignment.

(Other embodiments)
In the first and second embodiments including the first to third modifications, the example in which the coil 7 is started to be wound from the first ridge portion 51 located on the core segment 41 side which is the base end side of the tooth 42 has been described. Alternatively, the winding may start from the second ridge 52 located on the tip side of the tooth 42. In this case, the coil introduction groove 53 is provided in the second flange 52. In addition, although an example in which the coil 7 is formed of a winding having a circular cross section has been described, the invention is not particularly limited thereto. For example, the coil 7 having a square cross section may be used. Moreover, it does not specifically limit about the winding method of the coil 7, A general nozzle winding method, a flyer winding method, etc. can be used.

Moreover, although the insulator 5 is what is called a division type insulator and showed the example mounted | worn from the axial direction up-down direction of the tooth 42 respectively, it is not specifically limited to this, The coil winding part 50 is cylindrical shape, The integral structure which covers the whole outer peripheral surface of the tooth 42 may be sufficient. For example, when the stator 4 has a structure in which the tooth 42 is attached to the core segment 41 later, the insulator 5 having this integrated structure may be used. Moreover, the insulators 5 mounted from the upper and lower sides of one tooth may not have the same shape. In addition, the kind of insulator 5 can be decreased by using the thing of the same shape as insulator 5 with which one tooth is mounted from the upper and lower sides, and manufacturing cost etc. can be reduced.

The outer

circumferential surfaces

50 a and 50 b of the coil winding portion 50 may be provided substantially parallel to the axial upper end surface of the tooth 42. Further, the inner surface 51 a of the first flange 51 may be provided so as to be inclined radially outward with a surface orthogonal to the axial upper end surface or the axial lower end surface of the tooth 42 as a reference surface.

Further, it goes without saying that the insulator 5 in the first and second embodiments including the first to third modifications can be applied to the case where the coil 7 is wound in a single layer or in a multilayer.

In the first embodiment, the insulator 5 is attached to the tooth 42 of the core segment 41, and the coil 7 is wound around the coil winding portion 50 to form the stator segment 40a. May be attached to each of the teeth 42 of the annular stator core, and the coil winding portion 50 may be wound with the coil 7. In addition, the annular stator core said here is comprised laminating | stacking the board which pierce | punched the electromagnetic steel plate in annular shape. The annular stator core has a plurality of teeth (so-called teeth).

Also, in the first embodiment, an aspect in which each core segment 41 has one tooth (so-called tooth) has been described. However, for each core segment 41, a plurality of teeth (so-called teeth) are provided. You may employ the aspect which it has.

The motor 1 in the present specification is described for use in an inner rotor type motor, but it goes without saying that the insulator 5 of this embodiment can be applied to another type of motor.

Further, as shown in FIG. 3, two concave grooves are provided at the tip (radially inner end) of the tooth 42. The concave grooves are also referred to as supplemental grooves in, for example, US Pat. No. 6,104,117 and Japanese Patent Application Laid-Open No. 10-42531. The effect of the auxiliary groove suppresses cogging torque and torque ripple in the rotational operation of the rotor 3 of the motor 1, and contributes to the reduction of vibration and noise in the characteristics of the motor.

Moreover, the winding in

Embodiment

1, 2 is also called winding electric wire, and is marketed. The conductor portion of the winding or the wire for winding includes copper or aluminum containing unavoidable impurities. Here, the unavoidable impurities mean a trace amount of impurity elements which can not be avoided to be mixed into copper and aluminum during the manufacturing process. In the case of copper, unavoidable impurities include As, Bi, Sb, Pb, Fe, S, oxygen and the like. In the case of aluminum, unavoidable impurities are Si, Mn, Ti, V, Zr, Fe, Cu and the like. The conductor portion of the winding is covered with an insulating layer of insulating resin. As the insulating resin, for example, a polyimide, a polyamideimide, a polyesterimide, a polyesteramide imide, a polyamide, a polyhydantoin, a polyurethane, a polyacetal, an epoxy resin and the like are appropriately selected according to the specification of the motor 1. In addition to the circular shape in the present embodiment, the cross-sectional shape of the winding may be various, such as approximately square or approximately rectangular.

Further, the material component of the magnet 31 in the first embodiment contains at least one of Sc, Y and a lanthanoid element, Fe or Fe and Co, and B. Specifically, the magnet 31 is a rare earth sintered magnet, and is so-called neodymium sintered magnet or neodymium sintered magnet or the like. The surface layer of the rare earth sintered magnet is provided with a rust prevention film (rust prevention layer) for rust prevention.

INDUSTRIAL APPLICABILITY The insulator according to the present invention can realize aligned winding coils corresponding to coils with different wire diameters and winding numbers, and therefore is useful for application to a motor or the like that requires high efficiency.

Reference Signs List 1 motor 2 shaft 3 rotor 4 stator 5 insulator 6 insulating paper 7 coil 31 magnet 40 stator core 40 a stator segment 41 core segment 41 c yoke portion 42 tooth (tooth)
43 slot 50 coil winding portion 51 first ridge portion 51a inner surface of first ridge portion 51 second ridge portion 53 coil introduction groove 531 spacer introduction groove 54 spacer 55 spacer (string member)
56a spacer 56b spacer 57 spacer (film spacer)
58 spacer 58a U-shaped member 58b plate-like member 581 spacers U1 to W4 coil

Claims

A coil winding portion covering an axial end face of the tooth protruding from the core segment and at least a part of both circumferential side surfaces and in which a coil constituted by a winding is wound; and a tooth base end of the coil winding portion A first ridge portion continuously provided on one side of the side or the tip end of the tooth and having a coil introduction groove for guiding the coil to the coil winding portion, the tooth base end side of the coil winding portion or the tooth An insulator provided with a second flange portion provided continuously to the other on the tip side,
An insulator characterized in that a spacer for aligning the coil is attached to the coil winding portion and arranged in parallel to the coil.
In the insulator according to claim 1,
The difference between the radial length of the coil winding portion and the radial thickness of the spacer is equal to n times the wire diameter of the coil (n is an integer, the number of turns of the first layer of the coil) Insulator characterized by
In the insulator according to claim 1,
The coil is wound obliquely to the coil winding portion,
The thickness in the radial direction of the spacer is changed on the coil winding portion in accordance with the planned winding position of the final circumference of the first layer of the coil wound on the coil winding portion. Insulator characterized by
In the insulator according to claim 1,
The insulator is characterized in that the spacer is wound around the coil winding portion, and is formed of another wire member different from the coil.
In the insulator according to claim 1,
The insulator is characterized in that the spacer is integrally formed with the first ridge or the second ridge.
In the insulator according to claim 1,
The insulator is characterized in that the spacer is a single layer resin film having a predetermined thickness, or a laminate formed by laminating a plurality of the resin films.
In the insulator according to claim 1,
An insulator characterized in that the axial height H of the spacer is constant throughout the spacer.
In the insulator according to claim 1,
The axial height H of the spacer is constant over the entire spacer, and when the half value of the wire diameter of the coil is r,
An insulator characterized in that the height H satisfies the relationship H = r (1 + tan 30 °).
In the insulator according to claim 1,
An insulator characterized in that a surface of the coil winding portion is a smooth surface.
The insulator according to claim 1 is provided on each of axial end faces of the teeth of the core segment, and the coil winding portion of the insulator is provided with a plurality of stator segments formed by winding the coil.
A stator characterized in that a plurality of the stator segments are connected in an annular shape, and the teeth project radially inward of the annular ring.
The insulator according to claim 1 is provided on each of axial end faces of the teeth of the core segment, and the coil winding portion of the insulator is provided with a plurality of stator segments formed by winding the coil.
Including a configuration in which a plurality of the stator segments are connected in an annular shape, and the teeth project radially inward of the annular ring,
The stator is characterized in that the coils are wound in alignment around the coil winding portion.
The insulator according to claim 1 is provided on each of axial end faces of the teeth of the core segment, and the coil winding portion of the insulator is provided with a plurality of stator segments formed by winding the coil.
Including a configuration in which a plurality of the stator segments are connected in an annular shape, and the teeth project radially inward of the annular ring,
Between the teeth adjacent in the circumferential direction is configured as a slot for receiving the coil,
In the slot, an insulating paper for insulating the core segment and the tooth from the coil is partially overlapped in the axial direction with the first and second ridges of the insulator so as to cover the side surface of the tooth. A stator characterized in that it is arranged.
The insulator according to claim 1 is provided on each of axial end faces of the tooth of the core segment, and a plurality of stator segments including the coil wound around the coil winding portion of the insulator are provided. A stator including a configuration in which a plurality of the stator segments are connected in an annular shape, and the teeth project radially inward of the annular ring;
A motor comprising at least a rotor including a rotating shaft disposed radially inward of the stator at a predetermined distance from the stator.